Antimicrobial colloidal silver products and method of making same

ABSTRACT

Gelatinous materials combined with the Colloidal Silver additive to formulate an antimicrobial product having cushioning properties. Embodiments of the present invention can include gelatinous materials selected from a group consisting of thermosetting polymer, Styrene-Ethylene-Butadiene-Styrene polymer (SEBS), Thermoplastic Elastomer (TPE), and Polyurethane (PU) gelatin with and without a raised geometry on an outer surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is a Continuation Application of U.S.Non-Provisional application Ser. No. 13/151,937, entitled “ANTIMICROBIALCOLLOIDAL SILVER PRODUCTS AND METHOD OF MAKING SAME” filed Jun. 2, 2011,which claims benefit of U.S. Provisional Application Ser. No.61/350,626, entitled ANTIMICROBIAL COLLOIDAL SILVER PRODUCTS AND METHODOF MAKING SAME, filed on Jun. 2, 2010, all are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention is related generally to the field of antimicrobialproducts, and in particular antimicrobial colloidal silver products.

BACKGROUND OF THE INVENTION

Traditionally, TPE Gels (Thermoplastic Elastomers) are developed by thehydrogenation of tri-block co-polymers of styrene and butadene. Thepresent invention formulation allows for the glass transition of itsrubber block below-50° C. thus maintaining its rubbery properties. Thismaterial content gel is made up of visco-elastic properties that aretransformed into a gelatinous mass. The Tri-Block Co-Polymer, forexample, uses mineral oil as a plasticizer. TheStyrene-Ethylene-Butadiene-Styrene polymer (SEBS) description thenbecomes styrene and ethylene-butylene, and mineral oil is used for themodification of viscosity, and flexibility and strength of blends. Themajor applications for this type of gel have been for sealants,adhesives, coatings, footwear, athletic equipment, and other cushioningparts.

SUMMARY OF THE INVENTION

Generally, the present invention includes gelatinous materials combinedwith the Colloidal Silver additive to formulate an antimicrobial producthaving cushioning properties. Embodiments of the present invention caninclude gelatinous materials selected from a group consisting ofthermosetting polymer, Styrene-Ethylene-Butadiene-Styrene polymer(SEBS), Thermoplastic Elastomer (TPE), and Polyurethane (PU) gelatinwith and without a raised geometry on an outer surface.

For a better understanding of the present invention, together with otherand further objects thereof, reference is made to the accompanyingdrawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustratively shown and described in referenceto the accompanying drawings, in which:

FIG. 1 is a top view of an exemplary embodiment of a flat mat of thepresent invention, which has a top surface with a pluralitysemi-circular projections arranged in rows on a flat surface;

FIG. 2 is a end view of the exercise pad of FIG. 1;

FIGS. 3 and 4 are perspective views of an embodiment of the flat mat ofFIG. 1;

FIG. 5 is an end view of the flat mat of the embodiment of FIG. 1 rolledwith ends attached thereto;

FIG. 6 is a perspective view of the roller flat mat of FIG. 5 rotated ina counter-clockwise position;

FIG. 7 is a perspective view of the roller flat mat of FIG. 5 rotated ina clockwise position;

FIG. 8 is a side view of the roller flat mat of FIG. 5;

FIG. 9 is a perspective view of another embodiment of the presentinvention for an exercise roller, which has an outer surface with aplurality semi-circular projections arranged in rows and an inserttherein having opposing ends without semi-circular projections;

FIG. 10 is a perspective view of the exercise roller of FIG. 9 rotatedcounter-clockwise;

FIG. 11 is an end view of the exercise roller of FIG. 9;

FIG. 12 is a side view of the exercise roller of FIG. 9;

FIG. 13 is a side view of another embodiment of the present inventionfor an exercise roller, which has an outer surface with a plurality ofsemi-circular projections arranged in rows and an insert therein havingsemi-circular projections in proximity of the outer edges of the presentinvention;

FIG. 14 is an end view of the exercise roller of FIG. 13;

FIG. 15 is a flow diagram of the manufacturing process;

FIG. 16A is a side view of the present invention in the form of a flatmat without a plurality of semi-circular projections arranged in rows;

FIG. 16B is a perspective view of the flat mat of FIG. 16A;

FIGS. 17A is a side view of the flat mat in the form of a block withouta plurality of semi-circular projections arranged in rows;

FIG. 17B is a perspective view of the block of FIG. 17A;

FIG. 18 is a perspective view of the present invention in the form of aPilates mat with a plurality of semi-circular projections arranged inrows;

FIG. 19A is a top view of an alternative embodiment of a flat matillustrating an alternative projection with a square base section havingside that rise to form a semi-circular top section;

FIG. 19B is a side view of the alternative embodiment of FIG. 19A;

FIG. 20 is a flow diagram of the manufacturing process including theincorporation of the induction heating elements into the pre-fabricatedform to embed the induction heating elements within the gel material ofthe formed product; and

FIG. 21 is a flow diagram of the manufacturing process including theattachment of the induction heating elements to the gel material of theformed product.

DETAILED DESCRIPTION OF THE INVENTION

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about”, even if the term does notexpressly appear. Also, any numerical range recited herein is intendedto include all sub-ranges subsumed therein.

The phrase “cross-linked network” means the one polymer chain is linkedor bonded to another polymer chain.

The phrase “monolithic structure” means a solid, single part and not anassembly of two or more components.

The phrase “comprehensively suspended colloidal silver” means silverparticulates are suspended evenly throughout the gel material orsuspended unevenly but along a target surface, such as the outersurface, of the gel material, both of which provides sufficientantimicrobial protection for its intended purpose.

One embodiment of the present invention comprises a gelatinous materialwith a colloidal silver additive suspended substantially evenly withinthe gelatin material. The gelatinous material can either be athermosetting polymer, Styrene-Ethylene-Butadiene-Styrene polymer(SEBS), Thermoplastic Elastomer (TPE), or Polyurethane (PU) gelatin. Thethermo-reversible solid material is composed of a liquid organic phasedentrapped in a three-dimensionally cross-linked network. The solubilityof the liquid organic can add elasticity to a product creating ajelly-like substance or gelatinous material. The combination of organicmaterial plus SEBS material creates a thermoplastic elastomer. Thepolymers will be used in a final form in hardness and softness rangingfrom 0 to 40 on the shore A scale and harder consistencies on the ShoreDD Scale from 0 to 80. The range of the TPE Gels will be from 0 to 40 onthe 00 scale of measurement (Durometer). For the purpose ofillustration, one embodiment of the gelatinous material is:

Substance A: Polymeric Methylene diphenyl di-isocyanate (MDI) 100%;

Substance B: 265 Molecular weight (Mw) polyether triol 100%;

Ratio A:B about 1:1; and

Shore D about 80.

One method of preparing the present invention, illustrated in FIG. 15,treats a batch of gelatinous material with a suspended Colloidal Silveradditive (for example, SmartSilver™ manufactured by NanoHorizons, Inc.),which when loaded will totally penetrate all areas of each substance andprovide a green tinge to the color of the gelatinous material orplastic. A green tinge indicates that the silver additive has dispersedevenly in the material. The Colloidal Silver additive will inhibit thespread of over 650 bacteria strains including staph,Methicillin-resistant Staphylococcus aureus (MRSA), E-Coli and otherless well-known strains.

The prefabricated forms are allowed to set-up or air dry with verylittle pressure in order to derive the cast parts. The process ofpouring the gelatinous material at ambient pressure conditions (1atmosphere) and air casting is contrary to the conventional method ofinjection molding the gelatinous material under pressure conditions(above 1 atmosphere).

The next step is to mix the Colloidal silver additive in liquid orpowder form into the gelatinous material in the cast prior to the firstmelt stage. Thusly, the colloidal silver is dispersed into part A and Bof the A/B gelatinous material.

As stated above, the gelatinous material and Colloidal silver additiveare combined to form a gelatinous mixture through a cast/pouring method.The gelatinous mixture in the cast is heated to a predeterminedtemperature ranging from about 300 degrees F. to up to the boiling pointof the gelatinous material, and poured into prefabricated forms that arein the shape of the products to be derived from the casting of thematerials.

In one embodiment of the gelatinous material in pellet form, theColloidal silver additive is suspended simultaneously with the pellets,heated about 300 of , and poured into the prefabricated forms underambient pressures conditions (1 atmosphere) and not under pressure(above 1 atmosphere) as.

The resultant material derived from either process will be a gelatinousmaterial with comprehensively suspended colloidal silver throughout thegelatinous material. The final shape of the gelatinous material can takemany forms, examples of which are provided below. However, the scope ofthe present invention is not to be limited to the examples providedherein.

One embodiment of the present invention is illustrated in FIGS. 1-8illustrates a flat mat 2 and examples of its possible adaptableconfigurations. FIG. 1 is a top view of an exemplary embodiment being aflat mat 2 of the present invention; which has a top surface 4 with aplurality of semi-circular projections 6 arranged in rows 8 on a flatsurface 10. FIG. 2 is an end view of the flat mat 2 of FIG. 1. FIGS. 3and 4 are perspective views of an embodiment of flat mat 2 of FIG. 1illustrating cutout 12 along width 14 of bottom surface 16 at end 18 andcutout 20 along width 14 of top surface 10 at opposing end 22. FIGS. 1and 2 illustrate top surface cutout 20 having length 24 and depth 26substantially the same dimensions as bottom surface cutout 12 withlength 28 and depth 30, respectively, such that when flat mat 2 isrolled into a substantially circular form, as shown in FIG. 5, end 18and opposing end 20 are received into top surface cutout 20 and bottomsurface cutout 12, respectively. Another acceptable embodiment of ends18, 22 is any combination of cutout depths 26, 30 or end thicknesses 32,34 with a sum total thickness approximately equivalent to flat matthickness 36. Ends 18, 22 are removably attachable by any suitableattachment mechanism such as hook/loop, adhesive, male/female snaps, andclamps.

FIGS. 19A-B illustrate an alternative embodiment illustrating analternative mat 138 with projections 140 having a square base section142 with sides 44 that rise upward to blend with a semi-circular topsection 146.

FIG. 6 is a perspective view of the flat mat 2 in a rolled configurationas illustrated in FIG. 5 rotated in a counter-clockwise position.

FIG. 7 is a perspective view of the flat mat 2 in a rolled configurationas illustrated in FIG. 5 rotated in a clockwise position.

FIG. 8 is a side view of the flat mat 2 in a rolled configuration asillustrated in FIG. 5 showing longitudinal axis L that forms the centeraxis of the rolled cylinder.

Another embodiment of the present invention is an exercise roller 38illustrated in FIGS. 9-12 showing flat mat 2 wrapped around an insert 40connecting at overlapping end section 50 of ends 18, 22. FIG. 9 is aperspective view of embodiment 38 of the present invention, which has antop or outer surface 4 with a plurality semi-circular projections 6arranged in rows 8 and an insert 40 therein having opposing ends 42, 44without semi-circular projections 6. FIG. 10 is a perspective view ofexercise roller 38 of FIG. 9 rotated counter-clockwise. FIG. 11 is anend view of exercise roller 38 of FIG. 9 showing end surface 52. FIG. 12is a side view of exercise roller 38 of FIG. 9 illustrating length 51 ofinsert 40 relative to width 14 of flat mat 2. Insert 40 can beconstructed of foam or styro-foam. Diameter 48 of insert 40 issubstantially equivalent to length 46 of semi-circular projectionportion of flat mat 2 (see FIG. 1) plus overlapping end section 50,which is the longer of either top surface cutout length 24 or bottomsurface cutout length 28. Length 51 of insert 40 can be substantiallyequal to or greater than width 14 of flat mat 2. FIG. 12 illustrateslength 51 being greater than width 14. The embodiment where length 51equals width 14, which effectively eliminates opposing ends 42, 44without semi-circular projections 6, such that ends 52 are substantiallyadjacent to semi-circular projections 6.

Yet another embodiment of the present invention is a monolithic exerciseroller 54 without a diameter through a longitudinal axis L of theproduct illustrated in FIGS. 13-14 showing a cylinder 53 having diameter57 that can be constructed of foam, styro-foam, TPE, SEBS, PU andUrethane Gels, as well as silicone materials, with Colloidal Silveradditives suspended therein. Outer surface 56 of cylinder 53 has raisedgeometry 58 that traverses the entire circumference surface 55 invarious dimensional shapes and designs including but not limited toraised semi-circular bumps or projections as shown in FIGS. 13-14 inclose proximity of and adjacent to the outer edges 62, 64. Thismonolithic structure eliminates the need to wrap a substrate with theColloidal Silver suspended therein around the perimeter of the cylinder.

Yet another embodiment of the present invention is a monolithic exerciseroller 54 illustrated in FIGS. 13-14 showing a cylinder 53 havingdiameter 57 that can be constructed of foam, styro-foam, TPE, SEBS, PUand Urethane Gels, as well as silicone materials, with Colloidal Silveradditives suspended therein. Outer surface 56 of cylinder 53 has raisedgeometry 58 that traverses the entire circumference 55 in variousdimensional shapes and designs including but not limited to raisedsemi-circular bumps or projections as shown in FIGS. 13-14 in closeproximity of and adjacent to the outer edges 62, 64. This monolithicstructure eliminates the need to wrap a substrate with the ColloidalSilver suspended therein around the perimeter of the cylinder.

Examples of flat mat 2 can have total lengths defined as the sum of topsurface cutout length 24, bottom surface cutout length 28, andsemi-circular projection portion length 46 about 18 inches to about 26inches. Flat mat 2 can have widths about 14 inches to about 40 inches.However, lengths and widths longer or shorter are acceptable.

Examples of the exercise rollers 38, 54 can have lengths about 14 inchesto about 40 inches and diameters about 6 inches to about 8 inches.However, lengths longer or shorter and diameters larger or smaller areacceptable.

FIG. 16A is a side view of the present invention in the form of a flatmat 66 without a plurality of semi-circular projections arranged inrows. FIG. 16B is a perspective view of the flat mat 66.

FIGS. 17A is a side view of the present invention in the form of a block68 without a plurality of semi-circular projections arranged in rows.FIG. 17B is a perspective view of the block 68. An alternativeembodiment (not shown) of block 68 can include a plurality ofsemi-circular projections arranged in rows.

FIG. 18 is a perspective view of the present invention in the form of aPilates mat 70 with a plurality of semi-circular projections 6 arrangedin rows 8.

Yet another antimicrobial colloidal silver product according to thepresent invention is a shoe insert (not shown).

Alternative embodiments of the present invention for all products can becapability of generating heating. The products can be microwaveable orinclude induction heating elements power by AC or DC sources. Theinduction heating elements can either be embedded within the gelmaterial of the formed product (FIG. 20) or attached to an outer surfaceof the formed product (FIG. 21). The maximum temperature of the heatingelement is less than the boiling point of material, depending on thecomposition of the gel material.

Further alternative embodiments of the present invention for allproducts can be capable of being cooled to greater than the freezingpoint of the gel material such that the properties of malleability andcushioning are still present. The freezing point ranges depends on thecomposition of the gel material. The product can be place in therefrigerator or freezer to achieve the desired cooling temperature.

While the disclosure has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope of the embodiments. Thus, it isintended that the present disclosure cover the modifications andvariations of this disclosure provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. A product of the process comprising the steps of:loading a gelatinous material into a cast; loading Colloidal Silver intothe cast; heating the cast to a predetermined temperature to form amixture with Colloidal Silver evenly dispersed in mixture; pouringheated mixture into a prefabricated form that are in the shape of theproducts to be derived from the casting of the materials; air coolingthe prefabricated form; and removing the gel product with ColloidalSilver from the prefabricated form, wherein the gelatinous material is amixture of Substance A and Substance B at a ratio of A:B about 1:1,wherein Substance A is Polymeric Methylene diphenyl di-isocyanate (MDI)100% and Substance B is 265 Molecular weight (Mw) polyether triol 100%;and wherein the product is a flat mat.
 2. The product according to claim1, wherein the mat has raised geometric projections on at least onesurface of the mat.
 3. The product according to claim 2, wherein the matis an exercise mat.
 4. The product according to claim 1, wherein the matis rolled and joined at opposing ends to form a substantially circularroller.
 5. The product according to claim 4, wherein the circular rollerhas raised geometric projections on the outer surface of the roller. 6.The product according to claim 4, wherein the mat is rolled around aninsert.
 7. The product according to claim 6, wherein the circular rollerhas raised geometric projections on the surface of the roller.
 8. Theproduct according to claim 1, wherein the mat is a shoe insert.
 9. Aproduct of the process comprising the steps of: loading a gelatinousmaterial into a cast; loading Colloidal Silver into the cast; heatingthe cast to a predetermined temperature to form a mixture with ColloidalSilver evenly dispersed in mixture; pouring heated mixture into aprefabricated form that are in the shape of the products to be derivedfrom the casting of the materials; air cooling the prefabricated form;and removing the gel product with Colloidal Silver from theprefabricated form, wherein the gelatinous material is a mixture ofSubstance A and Substance B at a ratio of A:B about 1:1, whereinSubstance A is Polymeric Methylene diphenyl di-isocyanate (MDI) 100% andSubstance B is 265 Molecular weight (Mw) polyether triol 100%; andwherein the product is a cylinder.
 10. The product according to claim 9,wherein the cylinder has raised geometric projections on the surface ofthe cylinder.